Structured Problem Solving & Decision Making

Introduction

Objective

• Recognize the 7 wastes at the workplace for process improvement
• Understand the 7 Quality Control (QC) tools that can be used for continuous improvement
• Apply the 7 steps of root cause problem solving (RCPS) techniques
• Understand the CUTE principles
• Apply Edward De Bono's 6 Thinking Hats in making effective decisions

Key Content

Module 1: Introduction

• What is RCPS?
• Why do we need RCPS?
• How can we implement and gain benefits from it?
• RCPS relationship with Plan Do Check Act (PDCA)

Module 2: Self Diagnosis

• What is self-diagnosis?
• How to develop self-diagnosis?
  • Using 5 senses
  • Identify waste -seven (7) 'deadly' waste (TIMWOOD)
    • Transportation
    • Inventory
    • Motion
    • Waiting 
    • Over-processing
    • Over-production
    • Defects
  • Visual ideal states
  • Safety, Quality, Delivery., Cost, People - SQDC (P)
• Gemba Walk
  • Gemba skills
  • Tips for successful Gemba

Module 3: 7 QC (Quality Control) Tools

• What is quality
• What are 7 QC tools & the objectives
• The 7QC tools
  • Histogram - viewing the shape of dispersion or comparing with the specification
  • Pareto Diagram - selecting a major problem out of many
  • Check Sheet - quick data collection and prevention of mistakes
  • Fish Bone - possible cause and logical arrangement of causes
  • Scatter Diagram - seeing the relationship of pairs for variables
  • Control Chart - checking the stability of the process
  • Graphs - visual representation of data for quick understanding
• Brainstorming & 9 Box Grid
• Why why analysis

Module 4: Root Cause Problem Solving

• Fundamental
  • Elimination - not reduction
  • Visualization - getting a clearer picture
  • Following the process - without skipping the important steps
  • Knowledge sharing -  standardizations
• 7 Steps of RCPS
  • Problem Definition
    • Brief information
  • Problem Description & Goal Setting
    • Background
    • Quantify the problem - Who, What, When, Where, How, How much
    • Set goals (stretch)
  • Activity Plan
    • Timeline
    • Progress update
  • Root Cause Analysis
    • Identify point(s) of cause
    • Identify root cause
  • Corrective & Preventive Actions
    • Difference between corrective and preventive actions
  • Validate Effectiveness (Verifications)
    • Confirmed if goal(s) achieved
  • Standardizations (Fan Out)
    • Share learnings

Module 5: Decision Making

• The CUTE Principles
  • C - control your emotion
  • U - understand the problem from the right perspectives
  • T - think of the best possible solutions
  • E - evaluate your decisions
• Edward De Bono's 6 Thinking Hats
  • Blue - focus on the issues
  • White -  getting the right information 
  • Green - ideas for solutions
  • Gold - what are the advantages
  • Black - what are the disadvantages
  • Red - Feeling based on SCORE (if OBJECTIVE does not meet, what are the CAUSES? What are the SYMPTOMS? Assign RESOURCES and check if EFFECTIVE)